Keyboard Volume Controls working erratically

Hi,
I'm experiencing a strange issue with the mac keyboard volume controls. I have the system set to output both sound and sound effects to some external speakers via the line-out (set in System Prefs). Whenever I reboot my MacPro, the volume control keys stop working with the line-out and revert to controlling the built-in speaker. However, iTunes etc still output via the line-out.
If I try and reset the values in the System preferences, OS X switches the outputs around, but stubbornly leaves the volume keys controlling the internal speaker. If I switch to another User ID, then eveything works fine.
The volume keys had been working fine with the line out and external speakers until this morning...nothing new installed! So i'm puzzled as to why the sudden change! The only thing that was done differently before the shudown was to run the daily/weekly/monthly jobs, but they shouldn't have messed anything up.
I've tried the following 'fixes' which I've found in the forums, but without any permanent success:
1) Check Software Update - all up to date.
2) Reset PRAM - no effect at all.
3) Reset SMC - no effect at all.
4) Hold down power button until power light flashes - no effect at all.
5) Verify permissions - no effect at all.
6) Deleting the ~/Library/preferences/com.apple.BezelServices.plist file then logging out/rebooting. This resolves the issue until I reboot the Mac..then back to square one again. When I check the non-working bezelservices.plist against the one for the working User ID, there is no difference.
Anyone got any ideas on how to resolve this irritating bug - it's almost as bad as having a windows PC back again ?
MacPro 3Ghz Mac OS X (10.4.9)

I've been using SoundSource for a while now because I was having similar problems:
http://www.rogueamoeba.com/freebies/
I often switch between internal speaker, line out and imic depending on the time of day and what I'm listening to/watching.
SoundSource doesn't completely fix the problem but it does make it easier for switching outputs. I've found that if the kb controls get stuck on one output, I just switch the output in SoundSource to something else and then back to the preferred one and everything works again. Only takes a few seconds...

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Keyboard Volume Controls working erratically

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